Lean Six Sigma in a Manufacturing Lead Time Improvement Project

The objective of this research is to demonstrate the use of Lean Six Sigma methodology in a manufacturing lead time improvement project. Moreover, the goal is to develop working solutions for the target company to improve its manufacturing lead time. The theoretical background is achieved through exploring the literature of Six Sigma, Lean and Lean Six Sigma. The development will be done in collaboration with the related stakeholders, by following the Lean Six Sigma improvement process DMAIC and by analyzing the process data from the target company. The focus of this research is in demonstrating how to use Lean Six Sigma improvement process DMAIC in practice, rather than in comparing Lean Six Sigma to other improvement methodologies. In order to validate the manufacturing system’s current state, improvement potential and solutions, statistical tools such as linear regression analysis were used. This ensured that all the decisions were as heavily based on actual data as possible. As a result of this research, a set of solutions were developed and implemented in the target company. These solutions included batch size reduction, bottleneck shift, first-in first-out queuing and shifting a data entry task from production planners to line workers. With the use of these solutions, the target company was able to reduce its manufacturing lead time by over one third.

Lean toimenpiteiden implementointi PK-yrityksessä

Yritykset ympäri maailmaa ovat saavuttaneet Leanin avulla hyviä tuloksia ja parantaneet kilpailukykyään. Lean on kokonaisvaltainen filosofia, jossa käytetään konkreettisia työkaluja kehittämisen tukena. Implementonnin onnistuminen edellyttää koko organisaation sitoutumista muutoksiin ja uusiin toimintamalleihin. Meconet yhtio pyrkii maailman luokan toimittajaksi ja haluaa edistää toiminnan kehittämistä leanin periaatteiden mukaisesti hyödyntämällä kokonaisvaltaisia Lean työkaluja. Meconet Oy:n Vantaan tehtaalla oli keväällä 2013 tavoitteena edistää jatkuvaa kehittymistä Kaizenin avulla. Lisäksi tavoitteena oli ryhtyä järjestelmällisesti seuraamaan suorituskykyä mittareiden avulla ja lisätä visuaalisuutta. Meconet Oy:n Vantaan tehtaalla muodostettiin toimintamalli päivittäiseen suorituskyvyn seurantaan, toteutetttiin useita kehitysprojekteja Kaizen periaatteiden mukaisesti ja lisättiin visuaalisia elementtejä tiedonkulun parantamiseksi.

GLUT4 protein expression in obese and lean 12-month-old rats: insights from different types of data analysis

GLUT4 protein expression in white adipose tissue (WAT) and skeletal muscle (SM) was investigated in 2-month-old, 12-month-old spontaneously obese or 12-month-old calorie-restricted lean Wistar rats, by considering different parameters of analysis, such as tissue and body weight, and total protein yield of the tissue. In WAT, a ~70% decrease was observed in plasma membrane and microsomal GLUT4 protein, expressed as µg protein or g tissue, in both 12-month-old obese and 12-month-old lean rats compared to 2-month-old rats. However, when plasma membrane and microsomal GLUT4 tissue contents were expressed as g body weight, they were the same. In SM, GLUT4 protein content, expressed as µg protein, was similar in 2-month-old and 12-month-old obese rats, whereas it was reduced in 12-month-old obese rats, when expressed as g tissue or g body weight, which may play an important role in insulin resistance. Weight loss did not change the SM GLUT4 content. These results show that altered insulin sensitivity is accompanied by modulation of GLUT4 protein expression. However, the true role of WAT and SM GLUT4 contents in whole-body or tissue insulin sensitivity should be determined considering not only GLUT4 protein expression, but also the strong morphostructural changes in these tissues, which require different types of data analysis.

Balancing the quotation process by LEAN methods

This thesis studies the possibility to use lean tools and methods in a quotation process which is carried out in an office environment. The aim of the study was to find out and test the relevant lean tools and methods which can help to balance and standardize the quotation process, and reduce the variance in quotation lead times and in quality. Seminal works, researches and guide books related to the topic were used as the basis for the theory development. Based on the literature review and the case company’s own lean experience, the applicable lean tools and methods were selected to be tested by a sales support team. Leveling production, by product categorization and value stream mapping, was a key method to be used to balance the quotation process. 5S method was started concurrently for standardizing the work. Results of the testing period showed that lean tools and methods are applicable in office process and selected tools and methods helped to balance and standardize the quotation process. Case company’s sales support team decided to implement new lean based quotation process model.

Lean-projektin kannattavuuden ennalta-arviointi soveltamalla tuottojakauma-menetelmää

Tämän Pro Gradu-tutkielman tavoitteena on muodostaa työkalu Lean-projektin kannattavuuden ennalta-arvioinnin toteuttamiseen soveltamalla tuottojakauma-menetelmää. Lisäksi tutkimus pyrkii selvittämään, minkälaista siihen liittyvää akateemista tutkimusta on aikaisemmin toteutettu sekä mitä haasteita tämänkaltaisen arvion toteuttamiselle on. Tutkimuksen syntymistä on motivoinut Lean-pro-jektien kannattavuuden ennalta-arvioimisen akateemisesta tutkimuksesta tunnistettu tutkimusaukko. Empiirinen tutkimus on toteutettu kvalitatiivisena tapaustutkimuksena, yhteistyössä Lean-projekteihin erikoistuneen konsultointiyrityksen kanssa. Empiiristä tutkimusta on ohjannut sille valittu metodologia, jonka tavoitteena on ollut systemaattisesti muodostaa tutkimuksen tavoitteen mukainen työkalu. Aineistonkeruumenetelmänä on toiminut teemahaastattelu, joka on toteutettu kaksiosaisena. Niiden pohjalta saadut aineistot on analysoitu Grounded theory-menetelmää käyttäen. Tutkimuksen tulokset osoittavat, että muodostetulla tuottojakauma-menetelmää soveltavalla työkalulla on mahdollista toteuttaa Lean-pro¬jektin kannattavuuden ennalta-arviointi. Tulosten perusteella, sen avulla pystytään myös vastaamaan tutkimuksessa tunnistettuihin haasteisiin, jotka ovat aikaisemmin rajoittaneet tämän arvion toteuttamista. Työkalulla on mahdollista, tutkimuksen perusteella, myös tukea sen yhteistyöyrityksen Lean-projektien myyntiä.

Lean-ajattelu ratkaisuliiketoiminnan organisoinnissa

Teollisilla markkinoilla yhä useampi yritys pyrkii siirtymään ratkaisuliiketoimintaan. Kuitenkin muutos on osoittautunut vaikeaksi monissa yrityksissä, joissa toimintatapa on vakiintunut tuotekeskeiseen liiketoimintaan. Lean-ajattelua on menestyksekkäästi sovellettu moniin teollisuusyrityksiin, joissa on onnistuttu tehostamaan asiakasarvon tuottoa. Tämän pohjalta kandidaatin työn tavoitteena on tarkastella, miten lean-ajattelulla voitaisiin tehostaa ratkaisuliiketoimintaan siirtymistä. Työssä esitellään sekä ratkaisuliiketoiminnan että lean-ajattelun teoriaa, jonka pohjalta tarkastellaan lean-ajattelun soveltamismahdollisuuksia ratkaisuliiketoimintaan siirryttäessä. Lopuksi vertaillaan lean-ajattelun soveltamisen hyötyjä ratkaisuliiketoiminnan vaatimuksiin ja toisaalta haasteita, miten lean-ajattelu ei vastaa ratkaisuliiketoimintaa. Lean-ajattelun tukee parhaiten ratkaisuliiketoimintaa sekä asiakas- ja toimittajakeskeisyyden yhdistävän lean-ratkaisun kautta. Lisäksi lean-ajattelu tuo ratkaisuliiketoimintaa laajemman näkemyksen organisaation kehittämiseen. Haasteet liittyvät erilaiseen näkemykseen asiakkaan roolista liiketoiminnassa ja tarjoaman luomisesta.

Lean Methods and Digital Technologies in Healtchare

The experiences of several healthcare organizations were considered to distinguish the most frequently used lean tools, the success and failure factors, and the obstacles that may appear while implementing lean. As a result, two approaches to “go lean” were defined, and analyzed from the prospective of the applicability to healthcare processes. Industrialization of healthcare was studied, and the most promising digital technology tools to improve healthcare process were highlighted. Finally, the analysis of healthcare challenges and feasible ways to address them was conducted and presented as the main result of this work. The possible ways of implementation of the findings and limitations were described in the conclusion.

Customer involvement in lean startup principles: case of game development studio

The objective of this thesis is to better understand customer’s role in lean startup methodology. The aim is to find out how customers are involved in lean startup methodology implantation and increase the likelihood of new venture survival. This study emphasizes the usage of customers in shaping of new product development processes within companies, through iteration and constant communication. This communication facilitates the development of features that are requested by the customers and enhances the prospects of the new venture. The empirical part of the study is a single qualitative case study that uses action research to implement the lean startup methodology into a pre-revenue venture and examines its customer involvement processes. The studied case company is Karaoke d.o.o., developing a game called kParty. The study used the theory discussed in the literature review: customer involvement (in the survey and interviews conducted for the lean startup methodology), lean principles (through the implementation of lean startup methodology) and lean startup methodology, which are the central building parts of this thesis as a whole. The thesis contributes to the understanding of customer involvement in lean startup methodology, while giving practical implications of customer orientation and product market fitting.

The impact of industrial context and institutional factors on innovation and internationalization of Russian companies

Innovation and internationalization nowadays play significant role in formation of the competitive advantage for the companies and it is important to explore these processes deeply and use their potential. Such parameters, as industrial context and institutional factors, are essential parts of the business life and their influence may be crucial for the company’s performance. The Master’s Thesis explores impact of industrial context and institutional factors on innovation and internationalization of Russian companies. This research is quantitative and based on the analysis of the relevant scientific literature and results of the survey, conducted among Russian manufacturing companies. Findings show positive influence of industrial context factor “international threat” and institutional environment factor “lack of resources and the market imperfections” on internationalization of innovative Russian companies.

Varaosakunnostuksen tehokkuuden kartoittaminen ja lean-ajattelun soveltaminen kunnostusprosessiin

Tässä kandidaatin työssä analysoidaan kohdeyrityksen varaosakunnostuksen tehokkuutta ja havaitaan toiminnassa esiintyviä puutteita. Tutkimuksen tarkoituksena on nostaa esille toiminnassa esiintyvät kehityskohteet. Lisäksi tutkimuksessa arvioidaan Lean-ajatusmallin sovellettavuutta kunnostusprosessin kehittämiseen. Lopuksi Lean-ajatusmallin ja haastatteluissa esille nousseiden kehitysehdotusten pohjalta, kohdeyritykselle esitetään ehdotuksia menetelmistä toiminnan tehostamiseksi

Lean –synty ja kehitysvaiheet

Lean-filosofia ei ole syntynyt hetkessä vaan sen periaatteet ovat syvällä historiassa. Leaniin kuuluvia asioita kuten standardointia, oikeaan tarpeeseen vastaamista ja tuotannon virtausta on käytetty aikaisemmin erilaisissa sovelluksissa. Lean-käsitteen pohjana on Toyota Production System, joka oli syntynyt vaadittaessa kustannustehokasta tuotantoa niukin resurssein. Lean syntyi, kun yhdysvaltalaistutkijat kiinnostuivat Toyotan käyttämistä tavoista valmistaa monia erilaisia malleja tehokkaasti. Leania voidaan pitää vastakohtana massatuotannolle. Lean levisi kulovalkean tavoin läntisessä teollisuusmaailmassa, vaikka sitä ei välttämättä edes kokonaisuudessa sovellettu. Leanista eroteltiin selkeitä työkaluja, joilla yritykset pääsivät kehittämään toimintaansa ja tehostamaan prosesseja. Työkalut otettiin innokkaasti käyttöön valmistuksessa ja niille kehitettiin myös muita sovelluskohteita. Leanin perimmäinen filosofia jäi usein huomiotta, eivätkä kaikki saaneet odotettuja tuloksia. 2000-lukuun mennessä leanin periaatteet oli tutkittu jo läpikotaisin. Ymmärrettiin leanin implementoinnin koskeneen koko organisaatiota, jotta sen periaatteita voitiin toteuttaa tehokkaasti. Lean on kuitenkin tähän päivään mennessä yhä hieman vieras asia sisältönsä puolesta vaikka termi alkaa olla tuttu jo kaikille monilla eri aloilla. Leanin tutkimus jatkuu ja sille löydetään yhä uusia sovelluskohteita, osin ratsastetaan termin maineella, osin ymmärretään oikein virtaustehokkuuden merkitys asiakkaan palvelemisessa.

Innovation process development and business process integration - a multiple case study

The main objective of this study was to find out the bases for innovation model formulation in an existing organization based on cases. Innovation processes can be analyzed based on their needs and based on their emphasis on the business model development or R&D. The research was conducted in energy sector within one company by utilizing its projects as cases for the study. It is typical for the field of business that development is slow, although the case company has put emphasis on its innovation efforts. Analysis was done by identifying the cases’ needs and comparing them. The results were that because of the variances in the needs of the cases, the applicability of innovation process models varies. It was discovered that by dividing the process into two phases, a uniform model could be composed. This model would fulfill the needs of the cases and potential future projects as well.

Innovation Process and Organizational Adoption of Disruptive Innovation: Empirical Evidence from Finnish Bio-Economy Companies.

The thesis aims to build a coherent view and understanding of the innovation process and organizational technology adoption in Finnish bio-economy companies with a focus on innovations of a disruptive nature. Disruptive innovations are exceptional hence in order to create generalizations and a unified view of the subject the perspective is also on less radical innovations. Other interests of the thesis are how ideas are discovered and generated and how the nature of the innovation and size of the company affect the technology adoption and innovation process. The data was collected by interviewing six small and six large Finnish bio-economy companies. The results suggest companies regardless of size consider innovation as a core asset in the competitive markets. Organizations want to be considered innovators and early adopters yet these qualities are limited by certain, mainly resource-based factors. In addition the industry, scalability and Finland’s geographical location when seeking funding provide certain challenges. The innovation process may be considered relatively similar whether the idea or technology stems from an internal or external source suggesting the technology adoption process can in fact be linked to the innovation process theories. Thus the thesis introduces a new theoretical model which based on the results of the study and the theories of technology adoption and innovation process aims on characterizing how ideas and technology from both external and internal sources generate into innovations. The innovation process is in large bio-economy companies most often similar to or a modified version of the stage-gate model, while small companies generally have less structured processes. Nevertheless the more disruptive the innovation, the less it fits in the structured processes. This implies disruptive innovation cannot be put in a certain mould but it is rather processed case-by-case.

Gearing Towards Omnichannel Grocery Retail Through Business Model Innovation

Technological innovations and the advent of digitalization have led retail business into one of its biggest transformations of all time. Consumer behaviour has changed rapidly and the customers are ever more powerful, demanding, tech-savvy and moving on various plat-forms. These attributes will continue to drive the development and robustly restructure the architecture of value creation in the retail business. The largest retail category, grocery yet awaits for a real disruption, but the signals for major change are already on the horizon. The first wave of online grocery retail was introduced in the mid 1990’s and it throve until millennium. Many overreactions, heavy investments and the burst IT-bubble almost stag-nated the whole industry for a long period of time. The second wave started with a venge-ance around 2010. Some research was carried out during the first wave from a single-viewpoint of online grocery retail, but without a comprehensive approach to online-offline business model integration. Now the accelerating growth of e-business has initiated an increased interest to examine the transformation from traditional business models towards e-business models and their integration on the companies’ traditional business models. This research strove to examine how can we recognize and analyze how digitalization and online channels are affecting the business models of grocery retail, by using business mod-el canvas as an analysis tool. Furthermore business model innovation and omnichannel retail were presented and suggested as potential solutions for these changes. 21 experts in online grocery industry were being interviewed. The thoughts of the informants were being qualitatively analysed by using an analysis tool called the business model canvas. The aim of this research was to portray a holistic view on the Omnichannel grocery retail business model, and the value chain, in which the case company Arina along with its partners are operating. The key conclusions exhibited that online grocery retail business model is not an alterna-tive model nor a substitute for the traditional grocery retail business model, though all of the business model elements are to some extent affected by it, but rather a complementary business model that should be integrated into the prevailing, conventional grocery retail business model. A set of business model elements, such as value proposition and distribu-tion channels were recognized as the most important ones and sources of innovation within these components were being illustrated. Segments for online grocery retail were empiri-cally established as polarized niche markets in contrast of the segmented mass-market of the conventional grocery retail. Business model innovation was proven to be a considera-ble method and a conceptual framework, by which to come across with new value proposi-tions that create competitive advantage for the company in the contemporary, changing business environment. Arina as a retailer can be considered as a industry model innovator, since it has initiated an entire industry in its market area, where other players have later on embarked on, and in which the contributors of the value chain, such as Posti depend on it to a great extent. Consumer behaviour clearly affects and appears everywhere in the digi-talized grocery trade and it drives customers to multiple platforms where retailers need to be present. Omnichannel retail business model was suggested to be the solution, in which the new technologies are being utilized, contemporary consumer behaviour is embedded in decision-making and all of the segments and their value propositions are being served seamlessly across the channels.